Support Thin Gauge Slitter

3) Job Context & Major Challenges:

Job Context:

FRP- Phase 2 is for enhancing the Aluminium Flat Rolled Product capacity of Hindalco by additional 340 KTPA over 135 KTPA (Existing Hirakud FRP) to a total of 475 KTPA to cater to the growing requirement of high-quality products like Can Body Stock, Industrial Products, and Electronics in Asia, MENA, and East European Regions, in addition to meeting the domestic requirement. From the conception, this project is expected to have a second phase to fully utilize the inherent capacity of the hot mill, there by optimizing the productivity and resources to have the unique lowest cost position in the world FRP market.

Second Phase envisages commissioning in two phases of Phase 2A & Phase 2B with a total of two cold mills (One each in 2A & 2B) with all finishing facilities like, Tension levellers, Degreasing lines, Slitting Lines, Cut-to-length, Annealing furnaces, Roll grinding machines, Packing lines and Remelt furnaces with cast houses, making it a complete new Aluminium cold rolling mill complex. The hot rolled coils will be produced in the existing Hirakud FRP hot mill and will betransported to the new cold mill complex as an input material. In order to increase the Hot Mill capacity, One additional finishing mill stand, One new coiler and coil conveying system, 3 pusher type furnaces for slab heating and Edger at Roughing mill at the Hot Mill will be added.

The finishing lines process coils to achieve specifications such as customer specified width and weight of coil. They are also required to ensure that the surface defects along with gauge variations from upstream processes like Hot Mill and Cold Mill are detected, so that customer is not affected. Along with detection of upstream defects, finishing line also required to ensure that defects are not generated in finishing lines.

Finishing line equipment are the widest and biggest in terms of production and specifications amongst downstream units of Hindalco. Danieli Slitter has the capability to process coils of gauge ranging from 0.1mm to 1.5mm of coil weight upto 20MT. Danieli Slitter is the only slitting unit in India with Post Lub facility to process Can Body Stock Coils. It has CNC operated Center slitting unit. Cut To Length is also the widest sheet making line of Hindalco with processing capability of 6000mm/2100mm size capability. Cut To Length has one of its kind 6-High Sheet Leveling Unit along with one-of-its-kind automated vacuum stacker , cushion stacker for narrow and shirt length sheet stacking and CNC operated trimmer unit to process coil gauge ranging from 0.1mm to 1 mm. Apart from that there , Tension Leveler cum degreasing line which is having unique capability to process tension leveled aluminum coils with a degreased wash with Alkali and Acid medium. The coil gauge ranges from 0.1mm to 1mm and process width ranges from 700mm to 2100mm. Also there is multi slitting line that caters slit products least narrow is 40 mm while the thickness ranges from 0.3mm to 3mm along with an integrated slit packaging line. Moreover there is a circle blanking line that can produce blanks from diameter ranging from 170 to 650 mm and thickness ranging from 0.5mm to 6.5mm along with a disc packaging line. The finishing lines are attached to Coil Packing Line and Sheet Packing Lines are latest equipment with automatic packing operations.

This role is responsible for operating, controlling, and maintaining the slitter line used for cutting thin-gauge metal coils into specified widths while ensuring precision, quality, safety, and maximum equipment uptime. This role combines technical machine operation skills with hands-on maintenance capability to ensure continuous and efficient production.

The operator ensures proper setup of slitting knives, spacers, guides, and tension systems according to production requirements. They monitor key process parameters such as strip alignment, line speed, tension control, and recoiling conditions to prevent defects like burr formation, edge waviness, camber, telescoping, or strip breakage. Maintaining dimensional accuracy and protecting surface finish are critical aspects of the role.

In addition to operating the machine, the individual performs preventive maintenance activities including inspection, lubrication, cleaning, knife alignment, and minor mechanical adjustments. They identify early signs of wear, vibration, abnormal noise, or misalignment and take corrective actions to prevent breakdowns. For major mechanical or electrical faults, they coordinate with the maintenance team to minimize downtime.

The role also involves conducting quality checks to ensure slit coils meet width tolerances and customer specifications. Accurate documentation of production data, downtime, scrap levels, and maintenance activities is required to support traceability and performance analysis.

Safety is a major responsibility, as slitting operations involve rotating blades, sharp edges, and heavy coils. The operator must strictly follow safety procedures, lockout/tagout practices during maintenance, and maintain proper housekeeping standards.

Finishing Line has the main interface with theexternal customers and final authority to qualify the material for going to the customer and ensuring they are of world class standards. Hence, understanding of customers requirements is an important aspect of the role

This role is also responsible for monitoring maintenance of health, safety environment norms and statutory compliance with focus on maintaining pollution control norms for re-oiling and lubrication of cutters as well as packing materials. Imparting relevant training to the material handling operators to enforce compliance and prevent injury.

Job Challenges:

1. Thin gauge aluminum strip is highly sensitive to tension variation, misalignment, and improper handling. Even small errors can cause strip breakage, wrinkles, camber, edge waves, or surface scratches. Maintaining precise control throughout the slitting process is a continuous challenge. Customizing packing as per unique customer needs thereby introducing changes in machine and materials.
2. Achieving tight width tolerances and burr-free edges requires perfect knife setup, alignment, and spacing. Incorrect setup can result in customer complaints, rework, or rejection.
3. Monitoring knife condition, ensuring proper sharpening, and maintaining correct alignment requires technical skill and constant attention.
4. Mechanical issues such as bearing failure, shaft misalignment, hydraulic leaks, or tension control malfunction can cause unexpected downtime. The staff must quickly diagnose and perform minor repairs while coordinating major repairs efficiently.
5. Risk of cuts, entanglement, and crush injuries is high if safety procedures are not strictly followed.
6. Reducing changeover time without compromising accuracy is challenging.
7. Balancing production targets with preventive maintenance duties can be demanding, especially during tight production schedules.

4) Key Result Areas/Accountabilities:

Key Result Areas/Accountabilities

Supporting Actions

1. Business Excellence

• Machine uptime by reducing breakdown frequency.
• Reduced changeover time through better knife presetting and planning.
• Increased line efficiency (OEE improvement initiatives).
• To achieve daily/monthly production targets consistently.
• Preventive maintenance checklists.
• Identify early warning signs of bearing failure, misalignment, or vibration.
• To reduce unplanned downtime through proactive troubleshooting.

1. Cost

• Scrap & Yield Improvement by minimizing scrap generation
• Maintenance Cost Control by proper handling and maintenance of spare parts and consumables.
• Downtime Reduction by improving machine availability , TAT and reducing setup time.

1. Cash

• Working Capital Improvement by reducing WIP - minimize rework.
• Inventory upkeep by ensuring proper labeling and traceability to avoid dispatch errors
• Scrap Value Optimization by reducing unnecessary scrap generation.

1. Customer

• Supervising packaging to match customer expectations in terms of volumes, specification and quality
• Minimisingresponse time in providing information and solutions to all internal and external customers

1. Sustainability & Compliance

• Implementing compliance of all statutory and environmental norms with focus on environmental guidelines and manpower deployment
• Driving WCM, Kaizen and improvement projects for continuous improvement and greater sustainability
• Monitoring good housekeeping practices and green initiatives in area under jurisdiction

1. Safety

• Monitoring implementation of safety norms with respect to line operations
• Monitoring implementation of HIRA, JSA, LOTOTO and work permit systems
• Facilitating safety related training to own and contractual teams to embed a safety culture as per standardsand achieving zero incident
• Implementing emergency handling readiness through continuous review and course correction

1. People development and engagement

• Monitoring intake and deployment of appropriately trained contractual workforce in area under jurisdiction and ensuring their continuous training and wellbeing as per company guidelines.
• Facilitatingcompetency building and multiskillingthrough training initiatives to enhance technical and behavioral competencies towards greater productivity.

5) Role Specific Competencies

Technical competencies

• B Tech in Mechanical/Electrical/ECE/Metallurgy/Production with about 2 years of experience
• Understanding ofSlitting Process ,Knife Setup & Alignment ,Tension Control Expertise ,Machine Operation Skills ,Quality Inspection & Measurement ,Preventive & Basic Maintenance Skills ,Safety & Risk Awareness ,Basic Knowledge of TPM & 5S.